Ceiling construction or the like



May 3, 1966 C. L. ROBERTS ET AL CEILING CONSTRUCTION OR THE LIKE Filed Nov. 1'7, 1961 5 Sheets-Sheet l INVENTORS CHARLES L. ROBERTS GUS STRAUS ROBERT C. JOHNSON THEIR ATTORNEYS y 1966 c. L. ROBERTS ET AL 3,248,839

CEILING CONSTRUCTION OR THE LIKE Filed Nov. 1'7, 1961 3 Sheets-Sheet 2 27 FIG.?

INVE NTOR 8 CHARLES L. ROBERTS GUS STRAUS ROBERT C. JOHNSON THEIR ATTORNEYS y 966 c. L. ROBERTS ET AL 3,248,839

CEILING CONSTRUCTION OR THE LIKE Filed Nov. 17, 1961 5 Sheets-Sheet 5 INVENTO CHARLES L. R0 TS GUS STRAUS ROBERT C. JOHNSON THEIR ATTORNEYS United States Patent 3,248,839 CEILING CONSTRUCTION OR THE LIKE Charles L. Roberts and Robert C. Johnson, Louisville,

Ky., and Gus Straus, Richmond, Va., assignors to Reynolds Metals Company, Richmond, Va., a corporation of Delaware Filed Nov. 17, 1961, Ser. No. 153,098 3 Claims. (Cl. 52-484) This invention relates to improved ceiling constructions, such as false acoustical ceilings and the like, and to improved parts for such ceiling constructions or the like.

In the normal practice for making useful and decorative ceilings for offices, stores, homes and other building constructions or the like, a plurality of inverted T-shaped members are suspended a desired distance below a supporting ceiling structure in various patterns to receive decorative and/or sound deadening ceiling-s panels on adjacent cross-members thereof to fill the voids between the T-shaped members and complete the ceiling construction.

While such T-shaped suspension members can be made of any suitable material and in any suitable manner, the T-shaped suspension members are normally made by extruding metallic material, such as aluminum-containing metallic material or the like.

However, when it is desired to secure together two random lengths of the prior known T-shaped suspension members in aligned relation to form part of a ceiling construction or the like, rather complicated, expensive and time-consuming splicing methods are required.

Further, when it is desired to join an end of a prior known T-shaped suspension member to a border member secured to a vertically disposed wall or the like and forming an edge of the ceiling construction, rather complicated, expensive and time-consuming fastening methods are required.

However, according to the teachings of this invention an improved T-shaped suspension member is provided that can be readily spliced to an aligned T-shaped suspension member in a relatively simple and non-time consuming manner by an improved splicing member of this invention.

In addition, this invention provides an improved clip for readily attaching the T-shaped suspension member to a border member of the ceiling construction in a relatively simple and non-time consuming manner.

Accordingly, it is an object of this invention to provide an improved ceiling construction or the like having one or more of the novel features set forth above and hereinafter shown or described.

Another object of this invention is to provide an improved T-shaped suspension member for such a ceiling construction or the like.

A further object of this invention is to provide an improved splicing member for such a ceiling construction or the like.

Another object of this invention is to provide an improved fastening clip for such a ceiling construction or the like.

Another object of this invention is to provide an improved ceiling panel for such a ceiling construction or the like.

A further object of this invention is to provide an improved method for making such a ceiling panel or the like.

Other objects, uses and advantages of this invention are apparent from a reading of this description which proceeds with reference to the accompanying drawings forming a part thereof and wherein:

FIGURE 1 is a fragmentary, perspective view illustrat- 3,248,839 Patented May 3, 1966 ing one embodiment of the ceiling construction of this invention.

FIGURE 2 is a fragmentary perspective view illustrating the application of the improved T-shaped suspension member of this invention.

FIGURE 3 is an end view illustrating the improved splicing member of this invention.

FIGURE 4 is a side view of the splicing member illustrated in FIGURE 3.

FIGURE 5 is a fragmentary, perspective view illustrating the method of splicing together two aligned T-shaped suspension members of this invention by the splicing member of this invention.

FIGURE 6 is a crosssectional view taken on line 66 of FIGURE 5.

FIGURE 7 is a fragmentary, perspective view illustrating the manner of disposing the T-shaped suspension members of this invention at right angles relative to each other.

provide clip of this invention.

FIGURE 9 is a fragmentary side view illustrating the method of utilizing the clip of FIGURE 8 to secure the T-shaped suspension member of this invention to the border member of a ceiling construction or the like.

FIGURE 10 is a fragmentary perspective view illustrating the improved ceiling panel of this invention.

FIGURE 11 is a schematic flow diagram illustrating the method of making the ceiling panel of FIGURE 10.

While the various features of this invention are hereinafter described and illustrated as being utilized for forming a ceiling construction, it is to be understood that the various features of this invention can be utilized singly or in any combination thereof to form other types of constructions, as desired.

Therefore, this invention is not to be limited to only the embodiment thereof illustrated in the drawings, because the drawings are merely utilized to illustrate one of the wide variety of uses of this invention.

Referring now to FIGURE 1, an improved ceiling construction of this invention is generally indicated by the reference numeral 20 and comprises a plurality of longitudinally disposed T-shaped suspension members 21 of this invention suspended in inverted positions thereof from an upper ceiling supporting structure 22 by a plurality of wires 23 or the like in a manner hereinafter described, the longitudinally disposed T-shaped suspension members 21 being arranged in spaced parallel relation and having transversely disposed T-shaped suspension members 21' disposed therebetween and interconnected thereto in a manner hereinafter described.

The longitudinally disposed T-shaped suspension members 21 and transversely disposed suspension members 21' are respectively interconnected to border members 24 secured to the vertical walls 25 in a manner hereinafter described whereby the members 21, 21 and 24 have their bottom surfaces disposed in a common plane and define the framework of the ceiling construction 20.

A plurality of ceiling panels 26 are carried by the suspension members 21 and 21' and border members 24 and fill all the voids therebetween to complete the ceiling construction 20, the ceiling panels 26 comprising decorative and/or sound deadening structure as is conventional in the art.

While the suspension members 21 and 21' of this invention can be formed of any suitable material and in any suitable manner, the embodiments of the suspension members 21 and 21 illustrated in the drawings are formed by extruding metallic material, such as aluminum-containing metallic material or the like, into desired lengths by a conventional extruding apparatus or the like.

FIGURE 8 is a perspective view illustrating the im- As illustrated in FIGURE 2, each suspension member 21 or 21' has a substantially T-shaped cross-sectional configuration provided in part by a substantially straight cross-member 27 having the exterior surface 28 thereof suitably ribbed or provided with other decorative means or merely be plain, as desired.

Each T-shaped suspension member 21 or 21 has a substantially straight leg 29 provided with an olfset end 30 integrally interconnected to the cross-member 27 and perpendicularly disposed relative thereto, each leg 29 having an enlarged free end 31 provided with a substantially rectangular cross-sectional configuration.

A flange 32 extends substantially perpendicularly outwardly from the cross-member 27 of each suspension member 21 and 21' and is so spaced relative to the offset end 30 of the respective leg 29 that the same cooperates therewith to define a longitudinally disposed channel 33 for a purpose hereinafter described.

The legs 29 of the suspension members 21 are provided with a plurality of spaced and aligned apertures 34 intermediate the ends 30 and 31 thereof as illustrated in FIG- URE 2 to permit the suspension wires 23 to be looped around the suspension member 21 in the manner illustrated to suspend or otherwise secure the T-shaped suspension members 21 to the desired supporting structure, such as at 22 in FIGURE 1.

In order to fill the voids between adjacent suspension members 21, the ceiling panels 26 can have the opposed edges thereof disposed on adjacent halves of the crossmembers 27 of adjacent suspension members 21 in the manner illustrated in FIGURE 2. If desired, suitable clips 35 can be utilized to hold the ceiling panels 26 in place against the cross-members 27 of the suspension members 21 as illustrated in FIGURE 2, the clips not forming part of this invention.

If desired, the ceiling panels 26 can be suitably perforated at 36 so that sound below the ceiling construction 20 can pass through the perforations 36 and be absorbed by sound-proofing material 37 laid on top of the panels 26 in the manner illustrated in FIGURE 2. For example, the sound-proofing material 37 can comprise fiberglass blankets or the like of between one and two inches thick.

As previously set forth, one of the features of the T- shaped suspension members 21 of this invention is that the same can be readily spliced together in a relatively simple and non-time consuming manner by a splicing member of this invention.

The splicing member of this invention is generally indicated by the reference numeral 38 in FIGURES 3 and 4 and can be formed in any suitable manner and of any suitable material.

The embodiment of the splicing member 38 illustrated in the drawings is formed by extruding any suitable metallic material, such as aluminum-containing metallic material or the like, into desired lengths by a conventional extruding apparatus or the like.

The individual splicing member 38 is cut from the extruded stock and has a channel-defining portion 39 provided with a substantially rectangular cross-sectional configuration and having a longitudinally disposed slot 40 formed in one side thereof.

A leg 41 is integrally interconnected to the channeldefining portion 39 of the splicing member 38 adjacent the slot 40 and is angularly disposed relative to the adjacent side of the channel-defining portion 39, such as at an angle of approximately 4, for a purpose hereinafter described.

The leg 41 of the splicing member 38 has an offset free end 42 adapted to cooperate with the channels 33 in the T-shaped suspension members 21 in a manner herein after described.

As illustrated in FIGURES 3 and 4, a plurality of spaced and aligned projections 43 extend outwardly from the leg 41 of the splicing member on the side thereof adjacent the slot 40.

If desired, a second leg or flange 44 can extend outwardly in the opposite direction from the channel-defining portion 39 to provide means for suspending the splicing member 38. For example, the flange 44 can have an aperture 45 passing therethrough as illustrated in FIG- URE 4 to permit a wire 23 to suspend the splicing member 38 in the manner illustrated in FIGURE 5.

If the splicing member 38 is formed by an extrusion operation, it is believed best to extrude the splicing member stock with the L-shaped part 46 of the channel-defining portion 39 disposed in the position illustrated in dotted lines in FIGURE 3 to permit the splicing member stock to be extruded at a faster rate whereby the part 46 of the channel-defining portion 39 can be subsequently rolled to the position illustrated in full lines in FIGURE 3 in a subsequent operation to define the channel 47, the channel 47 being complementary to the enlarged free ends 31 of the T-shaped suspension members 21.

The individual splicing members 38 can be subsequently cut from the splicing member stock into desired lengths, such as between three and four inches, have the projections 43 punched formed, and have the legs 41 cut away at 38', FIGURE 4, to facilitate the splicing operation as will be apparent hereinafter.

When it is desired to splice together adjacent ends of aligned T-shaped suspension members 21, such as the suspension members 21a and 21b of FIGURE 5 by the splicing member 38, the channel 47 of the channel-defining portion 39 of the splicing member 38 telescopically receives the enlarged free end 31 of one of the suspension members 21a or 21b while the offset free end 42 of the leg 41 thereof is received in the channel 33 of that particular suspension member 21a or 21b. Thus, it can be seen that the splicing member 38 can be slipped onto the end of one of the suspension members 21a and 21b and moved relative thereto until the splicing member 38 is fully telescoped onto the particular suspension member 21a or 2112. Thereafter, the other suspension member 21a or 2112 is placed in aligned relation with the suspension member 21a or 21b carrying the splicing member 38 whereby the splicing member 38 can be moved outwardly to the position illustrated in FIGURE 5 to telescopically receive the end of that particular suspension member 21a or 21b by having the channel-defining portion 38 telescopically receiving the enlarged free end 31 thereof and the offset end 42 received in the channel 33 thereof, whereby the splicing member 38 overlaps the adjacent ends of the suspension members 21a and 21b and holds the same in aligned relation.

Because the leg 41 of the splicing member 38 is normally disposed at an angle relative to the channel-defining portion 39 thereof, the leg 41 is forced inwardly toward the legs 29 of the suspension members 21a and 21b when the free end 42 of the leg 41 of the splicing member 38 is received in the channels 33 whereby the leg 41 continually pushes outwardly against the flanges 32 of the suspension members 21a and 21b to frictionally hold the splicing member 38 in place and prevent the splicing member from sliding relative to the suspension members 21a and 21b after the same has been moved to the position illustrated in FIGURE 5.

Further, the projections 43 of the leg 41 of the splicing member 38 wedge against the legs 29 of the suspension members 21a and 21b to further tend to move the leg 41 of the splicing member 38 outwardly against the flanges 33 of the suspension members 21a and 21b to frictionally hold the splicing member 38 in the proper position on the spliced suspension members 21a and 21b.

In addition, the projections 43 on the leg 41 of the splicing member 38 tend to assist the person slicing the suspension members 21a and 21b to properly locate the splicing member 38 on the suspension members 21a and 21b by providing feel between the splicing member 38 and the suspension members 21a and 21b.

Therefore, it can be seen that the splicing members 38 of this invention are readily adapted to splice together aligned suspension members 21 in a relatively simple and non-time consuming manner whereby random lengths of suspension members 21 can be readily utilized to form any desired pattern of the ceiling construction 20 as the ends of the suspension members 21 need only be cut at substantially right angles relative to the cross-members 27 thereof to provide splicable ends thereof.

While the splicing member 38 illustrated in the drawings has a flange 44 projecting upwardly from the channeldefining portion 39 thereof in order to permit the suspension member 38 to be suspended by the wire 23 in the manner illustrated in FIGURE 5, it is to be understood that the flange 44 could be eliminated from the splicing member 38 because the legs 29 of the suspension members 21 provide means for suspending the assembly from a desired supporting structure as illustrated in FIGURE 2.

Further, should it be desired to suspend a pair of spliced suspension members 21 at the splicing member 38 having the flange 44 eliminated, a suitable aperture could be drilled through the leg 41 of the splicing member 38 and a corresponding portion of the leg 29 of one of the spliced suspension members 21 to provide means for tying a wire 23 thereto.

Should it be desired to form the ceiling construction 20 with transversely disposed suspension members 21', a suitable cut length of the T-shaped suspension member stock utilized to form the suspension member 21 has the cross-element 27 thereof cut away at 48 in the manner illustrated in FIGURE 7 so that the resulting transversely disposed suspension member 21 can have the end of the leg 29 thereof disposed on the adjacent half of the crossmember 27 of the longitudinally disposed suspension member 21 whereby the cross-members 27 of the suspension members 21 and 21 are disposed in a common plane.

As previously set forth, one of the features of this invention is to provide an improved clip for fastening the ends of the suspension members 21 and 21 to the border members 24 of the ceiling construction 20.

In particular, reference is made to FIGURE 9 wherein an improved border fastening clip of this invention is generally indicated by the reference numeral 49 and comprises a substantially U-shaped structure provided by a pair of opposed legs 50 and 51 respectively interconnected to the opposed ends of a spacing member 52.

The leg 50 of the clip 49 has a reversely turned end portion 53, and the leg 51 and the adjacent end of the spacing member 52 are suitably bifurcated to define two parts 51a and 51b of the leg 51 and two parts 52a and 52b of the spacing member 52.

Each part 51a and 51b of the leg 51 of the clip 49 is provided with an arcuate portion 54 to add resiliency thereto for a purpose hereinafter described.

As illustrated in FIGURE 9, the border member 24 comprises a substantially L-shaped member having one arm 55 thereof secured against a desired supporting structure, such as the wall 25, by fastening means 56 whereby the other arm 57 thereof extends outwardly from the supporting structure 25, the undersurface 58 of the arm 57 of the border member 54 being formed in a manner similar to the undersurface of the cross-member 27 of the suspension members 21, as desired.

The end of the suspension member 21 is disposed adjacent the arm 57 of the border member 24 with the cross-member 27 thereof disposed in the same plane as the arm 57 in the manner illustrated in FIGURE 9.

The clip 49 has the reversely turned end portion 53 of the leg 50 thereof hooked over the free end of the arm 55 whereby the clip 49 is attached to the border member 24 and has a portion of the spacing member 52 disposed adjacent the upper surface of the arm 57 of the border member 24.

The leg 29 of the T -shaped suspension member 21 is telescopically received between the bifurcated parts 51a and 51b of the leg 51 of the clip 49 and between the bifurcated parts 52a and 52b of the spacing member 52 of the clip 49 in the manner illustrated in FIGURE 8 whereby the spacing member 52 of the clip 49 is disposed against the cross-member 27 of the suspension member 21 while the free ends of the parts 51a and 51b of the leg 51 of the clip 49 engage against the enlarged free end 31 of the leg 29 of the suspension member 21. In this manner, the clip 49 is interconnected to the suspension member 21.

The arcuate portions 54 of the parts 51a and 51b of the leg 51 of the clip 49 permits the parts 51a and 51b of the leg 51 to be press fitted between the free end 31 of the leg 29 of the suspension member 21 and the crossmember 27 thereof to firmly hold the suspension member 21 in aligned relation with the border member 24.

Therefore, it can be seen that the fastening clips 49 of this invention readily permit the suspension members 21 and 21' of this invention to be interconnected to the border members 24 of the ceiling construction 20 in a relatively simple and non-time consuming manner, the prior art formerly requiring time-consuming bolts, welding and the like.

While the ceiling panels 26 utilized to form the ceiling construction 20 of this invention can have any desired configuration and be formed of any desired material, one type of ceiling panel of this invention that can be readily utilized to form the ceiling construction 20 or other ceiling constructions, as desired, is generally indicated by the reference numeral 59 in FIGURE 10 and comprises a sheet of metallic material, such as aluminum-containing metallic material or the like.

The ceiling panel 59 can be formed from a flat sheet 60, FIGURE 11, which is first passed through a perforating apparatus 61 comprising a perforating roll 62 and a backup roll 63 to perforate the sheet 60 with the desired pattern.

The perforated sheet 60 passes from the perforating apparatus 61 into station 64 whereby a normally exposed surface of the sheet 60 is provided with a decorative coating of enamel or the like in a conventional manner.

Thereafter, the sheet 60 is delivered to an embossing apparatus 65 comprising cooperating steel embossing rolls 66 which emboss the sheet 60 with the diamond pattern illustrated in FIGURE 10 whereby the diamond pattern adds rigidity to the ceiling panel, the diamonds having the apexes thereof extending outwardly from the ceiling panel 59 in the same direction.

Subsequently, the embossed sheet 60 is delivered to a corrugating apparatus 67 comprising a pair of cooperating corrugating rolls 68, such as steel rolls provided with suitable clearance at the nip thereof to corrugate the sheet 60 but to prevent damage to the diamond pattern thereon.

While the ceiling panel 59 of this invention is illustrated in FIGURE 10 as being perforated and coated, it is to be understood that the ceiling panel 59 of this invention can be unperforated, if desired, and can remain uncoated by not passing to the station 64 of the apparatus illustrated in FIGURE 11.

Therefore, it can be seen that this invention provides an improved ceiling panel 59 which has the desired structural strength thereof to be disposed between widely spaced suspension members 21 without having adverse sagging of the ceiling panel 59 because the diamond embossed pattern thereof rigidifies the ceiling panel 59.

Accordingly, it can be seen that this invention provides an improved ceiling construction as well as improved parts for such a ceiling construction or the like whereby ceiling constructions can be formed in a relatively simple and relatively non-time consuming manner from the various parts of this invention.

While the form of the invention now preferred has been disclosed as required by the statutes, other forms may be used, all coming within the scope of the claims which follow.

What is claimed is:

1. In combination, a pair of aligned suspension members for a ceiling construction or the like, each said suspension member having a substantially T-shaped cross-sectional configuration provided by a cross-member having an intermediate portion interconnected to an offset end of a leg, each cross-member having an outwardly directed flange cooperating with its respective ofiset end of said leg to define a longitudinally disposed channel, each leg of said suspension member having an enlarged free end, and an integral splice member having a portion thereof interconnected to said enlarged free ends of said suspension members by telescoping said enlarged free ends and having a leg provided with an offset free end telescoped and interlocked in said channels of said suspension members interconnecting said suspension members together in aligned relation.

2. A combination as set forth in claim 1 wherein said offset end of said leg of said splice member tends to move outwardly against said flanges of said suspension mem- 20 bers.

3. A combination as set forth in claim 1 wherein said portion of said splice member partly encompasses said enlarged free ends of said legs of said suspension members interconnected thereto.

References Cited by the Examiner UNITED STATES PATENTS 906,784 12/1908 Edeborg 52-630 1,096,218 5/1914 Berry 52-630 2,708,828 5/1955 Pruyn 189-36 X 2,829,743 4/1958 Strauss et al. 189-36 2,888,113 5/1959 Schwartz et a1. 52-28 2,934,184 4/1960 Moser 189-36 2,942,704 6/1960 Stubbs 52-476 2,964,148 12/1960 Jacobson 52-281 2,971,617 2/1961 Smith et a1 189-36 X 3,023,866 3/1962 Moore 52-489 3,089,570 5/1963 ONeil 189-36 RICHARD W. COOKE, ]R., Primary Examiner.

JOEL REZNEK, FRANK L. ABBOTT, Examiners.

W. L. SHEDD, R. S. VERMUT, Assistant Examiners. 

1. IN COMBINATION, A PAIR OF ALIGNED SUSPENSION MEMBERS FOR A CEILING CONSTRUCTION OR THE LIKE, EACH SAID SUSPENSION MEMBER HAVING A SUBSTANTIALLY T-SHAPED CROSS-SECTION AL CONFIGURATION PROVIDED BY A CROSS-MEMBER HAVING AN INTERMEDIATE PORTION INTERCONNECTED TO AN OFFSET END OF A LEG, EACH CROSS-MEMBER HAVING AN OUTWARDLY DIRECTED FLANGE COOPERATING WITH ITS RESPECTIVE OFFSET END OF SAID LEG TO DEFINE A LONGITUDINALLY DISPOSED CHANNEL, EACH LEG OF SAID SUSPENSION MEMBER HAVING AN ENLARGED FEED END, AND AN INTEGRAL SPLICE MEMBER HAVING A PORTION THEREOF INTERCONNECTED TO SAID ENLARGED FREE ENDS OF SAID SUSPENSION MEMBERS BY TELESCOPING SAID ENLARGED FREE ENDS AND HAVING A LEG PROVIDED WITH AN OFFSET FREE END TELESCOPED AND INTERLOCKED IN SAID CHANNELS OF SAID SUSPENSION MEMBERS INTERCONNECTING SAID SUSPENSION MEMBERS TOGETHER IN ALIGNED RELATION. 